ASU_APU_Adsorber 空分中的前端净化单元–分子筛筒

ASU_APU_Adsorber 空分中的前端净化单元–分子筛筒

AirCore Guidelines - Adsorber / 吸附器

Simulator Screenshot - iPhone17P 26.2 - 2026-07-11 at 10.53.36

1. TSA Principle / 变温吸附原理

Temperature Swing Adsorption (TSA) is the standard method for removing H₂O and CO₂ from air in ASU pre-purification units. The process alternates between adsorption (at process conditions) and regeneration (at elevated temperature). Dual-tower operation ensures continuous air supply: one tower adsorbs while the other regenerates. 13X molecular sieve selectively adsorbs CO₂, while activated alumina preferentially adsorbs H₂O.

变温吸附（TSA）是空分预纯化单元中去除空气中 H₂O 和 CO₂ 的标准方法。该工艺在吸附（工艺条件）和再生（高温）之间交替进行。双塔操作确保连续供气：一塔吸附时另一塔再生。13X 分子筛选择性吸附 CO₂，活性氧化铝优先吸附 H₂O。

\begin{gathered} \text{Adsorption: } A + B \rightleftharpoons A \cdot B + \Delta H_{ads} \\ \text{Desorption: } A \cdot B + Q \rightarrow A + B \\ \Delta H_{ads} > 0 \text{ (exothermic)} \end{gathered}

2. Adsorption Load Calculation / 吸附负荷计算

Water vapor load is calculated using Magnus formula for saturation pressure. At 35°C, P_sat ≈ 5.62 kPa. For saturated air (RH=100%), water mole fraction = P_sat/P_total. CO₂ load is based on ppmv concentration. Both loads are integrated over adsorption time to get total mass per cycle. Adsorbent mass can be auto-calculated from load and dynamic capacity (with safety factor), or manually specified in kg.

水蒸气负载使用 Magnus 公式计算饱和蒸气压。35°C 时 P_sat ≈ 5.62 kPa。饱和空气（RH=100%）的水摩尔分数 = P_sat/P_total。CO₂ 负载基于 ppmv 浓度。两种负载均在吸附时间内积分得到每周期总质量。吸附剂质量可根据负载和动态容量自动计算（含安全系数），也可手动输入（kg）。

\begin{gathered} P_{sat} = 0.6108 \cdot \exp\left(\frac{17.27 \cdot T}{T + 237.3}\right) \text{ [kPa]} \\ y_{H_2O} = \frac{P_{sat}}{P_{total}} \\ \dot{m}_{H_2O} = \frac{Q_{Nm^3/h}}{22.414} \cdot y_{H_2O} \cdot M_{H_2O} \\ M_{H_2O,cycle} = \dot{m}_{H_2O} \cdot t_{ads} \\ m_{Al} = \frac{M_{H_2O}}{C_{Al}/100} \times (1 + SF) \end{gathered}

3. Vessel Geometry / 容器几何尺寸

Vessel diameter is determined by H/D ratio and total adsorbent volume. Using Newton's method to solve the cubic equation derived from bed height and cross-sectional area. Head height = D/4 (standard 2:1 elliptical head). Shell height = bed height + top space (distribution zone). Total height = shell height + 2 × head height. Bed contact time is typically 8 seconds.

容器直径由高径比和吸附剂总体积决定。使用 Newton 法求解由床高和截面积导出的三次方程。封头高度 = D/4（标准 2:1 椭圆封头）。筒体高度 = 床高 + 顶部空间（分布区）。总高 = 筒体高度 + 2 × 封头高度。床层接触时间通常为 8 秒。

\begin{gathered} H_{total} = H/D \times D \\ H_{bed} = (H/D - 0.5) \times D - h_{top} \\ V_{bed} = \frac{\pi D^2}{4} \times H_{bed} \\ (H/D - 0.5) D^3 - h_{top} D^2 = \frac{4m}{\pi \rho_{bulk}} \end{gathered}

4. Vessel Design / 容器设计

Wall thickness is calculated using pressure vessel formula: t = PD/(2SE-P). Design pressure = operating pressure × 1.1. Allowable stress for 16MnR steel at 150°C is 137 MPa. Vessel mass = surface area × wall thickness × steel density (7850 kg/m³). Head area includes 1.084 correction factor for standard 2:1 elliptical heads. Vessel mass can be manually specified or auto-calculated.

壁厚使用压力容器公式计算：t = PD/(2SE-P)。设计压力 = 操作压力 × 1.1。16MnR 钢在 150°C 时的许用应力为 137 MPa。容器质量 = 表面积 × 壁厚 × 钢密度（7850 kg/m³）。封头面积包含 1.084 修正系数（标准 2:1 椭圆封头）。容器质量可手动指定或自动计算。

\begin{gathered} t = \frac{P_D \cdot D}{2(S \cdot E - P_D)} \\ P_D = P_{operating} \times 1.1 \\ A_{shell} = \pi D H_{shell} \\ A_{heads} = 1.084 \times \frac{\pi D^2}{2} \\ m_{vessel} = (A_{shell} + A_{heads}) \cdot t \cdot \rho_{steel} \end{gathered}

5. Pressure Drop - Ergun / 压降 - Ergun方程

Pressure drop is calculated using Ergun equation for both MS and Al layers. The equation accounts for viscous (low Re) and inertial (high Re) contributions. MS layer: dp=2mm, ε=0.38. Al layer: dp=3mm, ε=0.40. Total ΔP = ΔP_MS + ΔP_Al. Each layer's height is calculated from mass, bulk density, and cross-sectional area.

压降使用 Ergun 方程分别计算 MS 层和 Al 层。该方程考虑了粘性项（低 Re）和惯性项（高 Re）的贡献。MS 层：dp=2mm，ε=0.38。Al 层：dp=3mm，ε=0.40。总 ΔP = ΔP_MS + ΔP_Al。各层高度由质量、堆积密度和截面积计算。

\begin{gathered} \frac{\Delta P}{H} = \frac{150\mu(1-\varepsilon)^2 u}{\varepsilon^3 d_p^2} + \frac{1.75\rho_g(1-\varepsilon)u^2}{\varepsilon^3 d_p} \\ H_{MS} = \frac{m_{MS}}{\rho_{MS} \cdot A} \\ H_{Al} = \frac{m_{Al}}{\rho_{Al} \cdot A} \end{gathered}

6. Energy Balance Q1-Q5 / 能量平衡

Regeneration energy uses cold blow peak temperature (default 80°C) as the maximum bed temperature rise. Q₁ = vessel steel sensible heat, Q₂ = adsorbent sensible heat (MS + Al₂O₃), Q₃ = H₂O and CO₂ sensible heat, Q₄ = desorption heat (H₂O: 2500 kJ/kg, CO₂: 500 kJ/kg), Q₅ = heat loss (10%). Total heat Q_total = Q₁+Q₂+Q₃+Q₄+Q₅.

再生能量以冷吹峰值温度（默认 80°C）作为床层最高温升。Q₁ = 容器钢壳显热，Q₂ = 吸附剂显热（MS + Al₂O₃），Q₃ = H₂O 和 CO₂ 显热，Q₄ = 脱附热（H₂O: 2500 kJ/kg，CO₂: 500 kJ/kg），Q₅ = 热损失（10%）。总热量 Q_total = Q₁+Q₂+Q₃+Q₄+Q₅。

\begin{gathered} \Delta T = T_{cold\_blow\_peak} - T_{inlet} \\ Q_1 = m_{vessel} \cdot C_{p,steel} \cdot \Delta T \\ Q_2 = (m_{MS} \cdot C_{p,MS} + m_{Al} \cdot C_{p,Al}) \cdot \Delta T \\ Q_3 = (m_{H_2O} \cdot C_{p,H_2O} + m_{CO_2} \cdot C_{p,CO_2}) \cdot \Delta T \\ Q_4 = m_{H_2O} \cdot 2500 + m_{CO_2} \cdot 500 \\ Q_5 = 0.10 \times (Q_1 + Q_2 + Q_3 + Q_4) \end{gathered}

7. Heater Power / 加热器功率

Heater power heats regen gas from inlet temperature to heater set temperature: P = ṁ·Cp·(T_set-T_inlet)/η. Heating time = Q_total / P. Cold blow time = Q_cool / (ṁ·Cp·ΔT_gas). Remaining time for depressurize, repressurize, and parallel steps is split equally. Warning shown if depressurize time < 10 min.

加热器功率将再生气体从入口温度加热到设定温度：P = ṁ·Cp·(T_set-T_inlet)/η。加热时间 = Q_total / P。冷吹时间 = Q_cool / (ṁ·Cp·ΔT_gas)。降压、升压和并联的剩余时间平均分配。当降压时间 < 10 min 时显示警告。

\begin{gathered} P_{heater} = \frac{\dot{m} \cdot C_p \cdot (T_{set} - T_{inlet})}{\eta} \\ t_{heat} = \frac{Q_{total}}{P_{heater}} \\ t_{cool} = \frac{Q_{cool}}{\dot{m}_{cold} \cdot C_p \cdot \Delta T_{gas}} \end{gathered}

8. Cycle Timing / 循环时间

Dual-tower TSA cycle: Adsorption (fixed 180 min) + Regeneration (calculated). Regeneration steps: Depressurize → Heating → Cold Blow → Repressurize → Parallel. Heating and cooling times are calculated from energy balance. Depressurize, repressurize, and parallel times are split equally from remaining time. Total cycle = adsorption + regeneration = 360 min (6 hr).

双塔 TSA 循环：吸附（固定 180 min）+ 再生（计算）。再生步骤：降压 → 加热 → 冷吹 → 升压 → 并联。加热和冷吹时间由能量平衡计算。降压、升压和并联时间由剩余时间平均分配。总循环 = 吸附 + 再生 = 360 min（6 hr）。

\begin{gathered} t_{depress} = t_{repress} = t_{parallel} = \frac{t_{ads} - t_{heat} - t_{cool}}{3} \\ t_{regen} = t_{depress} + t_{heat} + t_{cool} + t_{repress} + t_{parallel} \end{gathered}

Default Parameters / 默认参数

Parameter / 参数 Default Value / 默认值 Unit / 单位
Heater Set Temperature / 加热器设定温度 180 °C
Regen Gas Temperature / 再生气体温度 40 °C (inlet + 5 / 进气温度+5)
Cold Blow Peak Temperature / 冷吹峰值温度 80 °C (regen gas + 40 / 再生气体+40)
Bed Contact Time / 床层接触时间 8 s
Design Velocity / 空塔气速 0.25 m/s
Safety Factor / 安全系数 0.4 -
Heat Loss / 热损失 10 %
Adsorption Time / 吸附时间 180 min

Generated from AirCore Adsorber Guidelines / 由 AirCore 吸附器指南生成

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